Case for an Electronic Device

ABSTRACT

A case ( 100 ) for an electronic device comprising: a front cover portion ( 101 ) including a first, external front cover panel comprising a hard material and a second external cover panel ( 101   b ), the second, smaller external cover panel ( 101   b ) and an internal, flexible material cover portion ( 104 ). The case comprises a rear portion ( 102 ) attached to the front cover portion ( 101 ), comprising an outer chassis portion ( 112 ) comprising the hard material and an inner chassis portion ( 114 ) comprising the flexible material, and one or more hinges ( 103 ) configured to allow the cover to open and close over an electronic device when the device is in the case ( 100 ), and wherein the one or more hinges ( 103 ) are formed by channel or groove ( 119 ) formed on an inside face of the flexible material cover portion. The case includes an opening ( 117 ) in the rear portion ( 102 ) case ( 100 ) to allow operation of a camera for the device, wherein the front cover when in a fully open position does not block the camera opening.

The present application claims priority from U.S. Provisional Application No. 62/087,376 filed on Dec. 4, 2014, the disclosure of which is incorporated herein by reference in its entirety.

DESCRIPTION OF RELATED TECHNOLOGY

A case or cover for an electronic device such as a smart phone, cell phone, GPS unit, MP3 player, tablet, camera, or laptop computer.

SUMMARY

According to an embodiment, disclosed is a case or cover for an electronic device comprising: a front cover portion 101 including a first, external front cover panel comprising a hard material and a second external cover panel 101 b, the second, smaller external cover panel 101 b and an internal, flexible material cover portion 104. The case comprises a rear portion 102 attached to the front cover portion 101, comprising an outer chassis portion 112 comprising the hard material and an inner chassis portion 114 comprising the flexible material material, and one or more hinges 103 configured to allow the cover to open and close over an electronic device when the device is in the case 100, and wherein the one or more hinges 103 are formed by channel or groove 119 formed on an inside face of the flexible material cover portion. The case includes an opening 117 in the rear portion 102 case 100 to allow operation of a camera for the device, wherein the front cover when in a fully open position does not block the camera opening. The one or more hinges 103 can a bend radius of at least about 90 degrees or more, and can be configured to allow the panels 101 a, 101 b to open and be rotated about the spine 106 and back of the case 100.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are illustrated in the figures of the accompanying drawings, which are meant to be exemplary and not limiting, and in which like references are intended to refer to like or corresponding things.

FIGS. 1A-14 show orthographic views of an embodiment of the case.

FIGS. 1A-1C show an embodiment of a case shell assembly and front portion cover for a case.

FIG. 1C′ is another view of the embodiment of FIG. 1C.

FIGS. 2A-6 show an embodiment a front portion cover for the case.

FIG. 6′ is another view of the embodiment of FIG. 6.

FIGS. 7A-9 show an embodiment including a rear portion comprising a chassis sub-assembly.

FIG. 10 shows an exploded view of an embodiment of the case shell and front portion cover assembly.

FIGS. 11A-11G show a molding process can be employed to make the case.

FIGS. 10′-12′ and 14′ are additional views of the embodiments of FIGS. 10-12 and 14 respectively.

FIGS. 15 and 16 show an embodiment with a snap closure 130 to hold the cover closed to reduce the likelihood of it opening accidentally.

FIG. 17 shows a chassis side of the snap of the snap closure 130.

FIG. 18 shows one side of the cover snap of the snap closure 130.

FIG. 19 shows an embodiment where the finger tab of the snap closure 130 is extended to make it easier to open and close the case.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Disclosed are embodiments of a protective case 100, faceplate, or other protective covering for an electronic device (not shown). As used herein a protective “case” or “cover” broadly encompass all forms of protective coverings and parts thereof for personal electronic devices as known in the art, including cases, skins, faceplates, shields or covers applied to the device for protection or style. Embodiments described herein are not limiting but are offered to give a clear understanding of the invention, which can be employed in all such protective cases or covers. Exemplary personal electronic devices include those referred to herein, including mobile telephones, so called “smart phones” (e.g., iPhone™ Android™ or Blackberry™), laptop computers, tablet computers, digital audio players, GPS units, MP3 players, tablets, cameras, and the like.

Described is a case that provides all-over protection with an integrated co-molded folio cover. The cover nests to the case, and has two parallel molded rubber hinges. In an embodiment a spine-located hinge allows the cover to open from the case, and a second mid-located hinge allows it to bend around the case to a parallel position. The cover can be configured to stop short of a camera opening as to not block it. The hinges made of the flexible material also act as a spring to close the cover, allowing the case to close itself.

FIGS. 1A-14 show orthographic views of an embodiment of the case 100. As shown in FIGS. 1A-1C and FIG. 10, the case 100 includes shell assembly including front cover portion 101 for covering a front of an electronic device and a rear portion 102 for covering back of a personal electronic device. The same reference numbers are used for the same features throughout unless the context indicates otherwise.

FIGS. 2A-6 show a front portion 101 assembly for the case 100. The front portion 101 forms an external front cover for the electronic device, and comprises a first, external front cover panel 101 a, views of which are shown at FIG. 3A, and a second external cover panel 101 b, the second external panel cover 101 b being smaller than the first external cover panel 101 a, views of which are shown at FIG. 3B. The first and second external panel covers 101 a, 101 b can be made from a hard material, for example an engineering plastic such as polycarbonate. The hard material can be selected, for example, to provide impact and scratch resistance.

The front portion 101 also includes an internal, flexible material cover portion 104, a view of which is shown at FIG. 4. In an embodiment the inner flexible material portion has a hardness of about 65 shore A, but is not limited thereto. The internal flexible material cover portion 104 can include a texture, such as perforations or a molded or formed pattern, on the inner face of the cover 101.

The inner flexible material cover portion 104 also forms one or more hinges 103 for the front cover by the front portion 101 which allows the cover to be opened and closed over the face of the device when placed in the case 100. As shown in the embodiment of FIGS. 1C and 6, the one or more hinges 103 can a bend radius of at least about 90 degrees or more, and can be configured to allow the panels 101 a, 101 b to open and be rotated about the spine 104 and back of the case 100. The hinges made of the flexible material, such as for example an elastomeric material, also act as a spring to close the cover, allowing the case 100 to close itself.

For example, in an embodiment the front portion 100 can comprise a plurality of hinges 103 a, 103 b, for example a spine hinge 103 a along an axis between the stiffener and the second cover panel 101 b, and a face cover hinge 103 b along an axis between the first external, cover panel 101 a and the second external cover panel 101 b. The external front portion 101 and internal flexible material cover portion 104 form a flush external surface of the cover 101 of the case 100 at the one or more hinges 103 where the flexible material of the inner flexible material cover portion 104 extends between the first and second external panel covers 101 a, 101 b at the axes. The one or more hinges 103 can be formed by channel or groove 119 formed on an inside face of the flexible material cover portion. For example, as shown in FIG. 2B, FIG. 4, and FIG. 6, the spine hinge 103 a is shown as a channel 119 a on the inside face of the flexible material between at the spine hinge between second cover panel 101 b and the stiffener 105; the channel is angled so as to allow the front cover to fold back about 90 degrees or more. The face cover hinge 103 a is shown as a triangular groove 119 b formed on the inside face of the flexible material between the first cover panel 101 b and second cover panel 101 a. For example, in an embodiment the spine hinge 101 b can be configured to have a bend radius of at least 90 degrees to 270 degrees, allowing the panel 101 b to rotate and substantially lay against the spine 106, and the face cover hinge 101 a can rotate from hinge 103 b such that it lays against the back of the rear portion 102 of the case 100.

In an embodiment the case 100 comprises a stiffener portion 105, the stiffener portion adapted to mechanically connect to the inner flexible material cover portion 104 along a spine 106 of the case 100 and connect to the rear portion 102 of the case. FIG. 5 shows views of the stiffener 105. The spine 106 of the case 100 can be formed by the stiffener portion 105 and the inner flexible material portion 104. The stiffener portion 105 can be configured to mechanically connect to the rear portion 102 of the case. Alternatively or additionally adhesive or other methods of bonding can be employed.

In an embodiment the inner flexible material portion 104 of the spine 106 of the case 100 includes flexible material button covers that allow inputs on the side of the electronic device to be operated when the electronic device is in the case.

In an embodiment, an opening in the case 100 to allow operation of a camera for the device. The opening can include a flash insert 111, for example as described in U.S. patent application Ser. No. 12/890,603 entitled Flash Insert for Mobile Phone Case, filed on Sep. 25, 2010 the entirety of which is incorporated by reference hereby. An embodiment of an exemplary flash insert 111 is shown at FIG. 13.

The case 100 includes a rear portion 102, for example a chassis comprising an exterior substrate 112 at least one interior layer 114. An example of a case with more than one layer including an exterior layer and interior layer is disclosed in U.S. patent application Ser. No. 12/366,769, filed on Feb. 6, 2009 and issued as U.S. Pat. No. 8,755,852, entitled “One Piece Co-formed Exterior Hard Shell Case with an Elastomeric Liner for Mobile Electronic Devices,” the entirety of which is incorporated by reference hereby. The protective case 100 can include an outer layer formed from the substrate 112 of the protective case 100, comprising two (or more) separate layers, a first external hard shell layer 101 and a second interior flexible material layer 114. The first external hard shell layer 112 and a second interior flexible material layer 114 can be combined to independently attach to the electronic device 120.

The handheld device protective case depicts the external hard shell layer 112 with cut corners 116 and inner flexible material layer 114 of the protective carrying case where the inner flexible material layer 114 fills in the cut corners 116 of the external hard shell layer 112. In the embodiment, to allow the external hard shell layer 101 to be able to be mounted on a device, the corners 116 of the external hard shell layer 112 are cut open. This allows each sidewall of the external hard shell layer 112 to flex away when a device is inserted and snap back once it is in place. An inner flexible material layer 114 is formed in addition to the external hard shell layer 101 on the interior of the external hard shell layer 112. The inner flexible material layer 114 fills in the gaps created at the corners 118 of the external hard shell layer 101 to allow the external hard shell layer 102 to flex during mounting.

The inner flexible material layer 114 provided in this location has greater inherent flexibility than the plastic or metal of the external hard shell layer 112 and it stretches sufficiently to allow the sidewalls of the external hard shell layer 112 to still flex away on mounting. This creates a protective case 100 that wraps around a device even on corners and prevents dirt and fluids from entering wherever possible. The inner flexible material layer 114 also can be formed over the buttons on a device wherein a user simply presses the exposed inner flexible material layer 114 at a port opening corresponding to the portion of the mobile electronic device input.

FIGS. 7A-9 show an embodiment including the rear portion 102 comprising a chassis sub-assembly. The rear portion 102 chassis comprises an outer chassis portion 112 comprising the hard material, shown in FIG. 9, and an inner chassis portion 114 comprising the flexible material, shown in FIG. 8. The inner chassis portion 114 can includes a texture, such as perforations or a molded or formed pattern, formed in the flexible material. The inner chassis portion 114 includes an open area 115 for attaching the cover to the outer chassis portion 112 and mechanically connecting the stiffener portion 105 to the rear portion 102 chassis. Alternatively or additionally adhesive or other methods of bonding can be employed.

In an embodiment the inner flexible material cover portion 104 forms an inner layer 107 along the portion of the stiffener portion 105 that attaches to the rear portion 102 chassis such that it completes the open area 115 formed by the inner flexible material chassis portion 114 of the rear portion 100 chassis. In an embodiment, the inner layer can be textured to match the inner chassis portion 114 comprising the flexible material.

Exemplary non-limiting advantages of the case 100 are that is provides all-over protection with an integrated co-molded folio cover. The front portion 101 cover nests to the to the rear portion 102 of the case 100, and in embodiments has two parallel molded flexible material hinges 103 a, 103 b. A spine-located hinge 103 b allows the front portion 101 cover to open from the case, and a mid-located hinge 103 b allows it to bend around the case to at least a parallel position. The cover then stops short of a camera opening 117 as to not block it. The rubber hinges 103 a, 103 b also act as a spring to close the cover. Another advantage is all-over protection. The dual-layer flip cover shields an electronic device from scratches, bumps and drops for 360-degree defense. The case 100 also prevents smudges and scratches on the screen all while increasing a sense of privacy. The folding front cover 101 also can allow for comfortable one-handed use. Embodiments also allow for military-grade protection as the hard outer shell guards against impact, while soft, rubbery interior and reinforced corners absorb shock. The case 100 can meet or exceed MIL-STD 810G drop-test standards.

In an embodiment the case (100) is substantially opaque, although embodiments can also include transparent or partially transparent cases for example using transparent plastics.

In an embodiment, case 100 is constructed such that the phone can be used when the front cover 101 is closed. For example, in an embodiment a telephone speaker opening 120 is made in the front cover 101 such that it is positioned over or operatively near the location of a telephone speaker in the electronic device when the device is in the case and covered by the front cover 101. This allows a user to hear the speaker. The case 100 microphone opening 121 is formed in the case 100 to be positioned over or operatively near the location of a microphone in the electronic device when the device is in the case, which allows the user to speak into the device microphone through the case 100. As such, the case 100 is constructed to allow a user to use, inter alia, the telephonic function of the electronic device.

The material used for case 100 can be selected from the following list (or their combinations): plastic, elastic material, rubber, any artificial material, rigid, soft, flexible, wood, glass, mirror, smooth, rough, coarse material or surface, metal, alloy, nylon, cotton, wool, fabric, natural material, convex, concave, flat surface, quartz, transparent, translucent, opaque material, uniform, or non-uniform surface.

For example the hard material can be engineering plastic (e.g. polycarbonate, acrylonitrile butadiene styrene (ABS)), metal, wood, hardened plastic or other rigid material. The flexible material can be, for example elastomeric material, rubber, silicone, thermoplastic elastomers (TPE), flexible thermoplastic polymers such as polypropene, or other flexible plastics as known in the art.

FIG. 10 shows an exploded view of the case, which can be made as shown in FIGS. 11A-11G. FIGS. 11A-11G show a molding process can be employed to make the case, as for example by injection molding. As shown at FIG. 11A, the process can comprise molding an outer chassis portion 112 comprising a hard material. In an embodiment as shown in FIG. 12 the process can include removing one or more slides from the molded outer molded chassis portion at an angle normal to the curvature of the sides of the outer molded chassis portion. The method can also include removing lifters at an angle relative to the snap geometry of the case, wherein the lifters are positioned so as not to cross an opening for the camera of the electronic device or the adhesive bond areas for other portions of the case. As shown at FIG. 11B, the method can include affixing a flash insert 111 to the outer chassis portion. As shown at FIG. 11C the method then can include overmolding the outer chassis portion 112 with the inner chassis portion 114 comprising the flexible material.

As shown at FIG. 11D, in an embodiment the method then comprises molding the one or more face covers 101 a,101 b, and the at FIG. 11E, affixing the stiffener portion 105 in the molding tool. As shown at FIG. 11F, then method then comprises overmolding the one or more face covers 101 a, 101 b with the internal, flexible material cover portion 104.

As shown at FIG. 11G, in an embodiment the method includes mechanically connecting the cover including the stiffener 105 to the chassis. In an embodiment, the stiffener is connected to the outer chassis portion 112. For example, the stiffener 105 and the outer chassis portion 112 can be configured to connect in a snap-fit configuration or other such mechanical connection as known in the art. Alternatively or additionally adhesive or other methods of bonding can be employed.

The method can include mechanically connecting the stiffener portion 105 to the inner flexible material cover portion 104 along a spine 106 of the case 100.

In embodiments, the case is molded such that the external front cover 101 includes a registration channel along an outer perimeter of the interior face of the front cover for registering a molding tool during an overmolding process.

As shown in FIG. 14, in embodiments, the molding tool is configured such that a gate for the chassis is located in along a center axis of the flow tie and is gated from a cavity side. The gate may not be in a center area of the chassis such that the likelihood of warping of the case is decreased. For example, a gate can be located at least about 20 mm from an image on the inside of the case.

In embodiments a fan gate for the case or cover 100 is positioned along at least one of the face cover hinges 103 b.

In embodiments a pin gate is located on the external front cover 101 such that it is overmolded or covered by the internal, flexible material cover portion 104. In embodiments a pin gate is located on the internal, flexible material cover portion 104 such that it is camouflaged by the textured area or hidden. In embodiments a pin gate is hidden on the spine area of the internal, flexible material cover portion 104.

In embodiments the tool is configured and/or the case is molded such that no ejector marks are located on cosmetic surfaces of the finished case 100.

It is appreciated that the optimum dimensional relationships for the parts of the invention, to include variation in size, materials, shape, form, function, and manner of operation, assembly and use, are deemed readily apparent and obvious to one of ordinary skill in the art, and all equivalent relationships to those illustrated in the drawings and described in the above description are intended to be encompassed by the present invention.

Furthermore, other areas of art may benefit from this method and adjustments to the design are anticipated. Thus, the scope of the invention should be determined by the appended claims and their equivalents, rather than by the examples and embodiments given. 

1. A case (100) for an electronic device comprising: a front cover portion (101) comprising a first, external front cover panel (101 a), the first external cover panel (101 a) comprising a hard material; a second external cover panel (101 b), the second, external cover portion (101 b) comprising the hard material, the second external panel cover (101 b) being smaller than the first external cover panel (101 a); an internal, flexible cover portion (104), a rear portion (102) attached to the front cover portion (101), comprising: an outer chassis portion (112) comprising the hard material an inner chassis portion (114) comprising the flexible material, one or more hinges (103), the one or more hinges (103) configured to allow the cover to open and close over an electronic device when the device is in the case (100), the one or more hinges being configured to allow the first and second panels (101 a, 101 b) of the front cover portion (100) to open and be rotated about a spine (106) and the rear portion (102) of the case
 100. 2. The case (100) of claim 1, the case (100) further comprising: a plurality of hinges (103 a, 103 b) including: a spine hinge (103 a) along an axis between the stiffener and the second cover portion, and a face cover hinge (103 b) along an axis between the first external, cover panel and the second external cover panel.
 3. The case (100) of claim 2, wherein the spine hinge (103 a) allows the cover (101) to open from the case (100), and the second face cover hinge allows the cover (101) to bend around the case (100) to a parallel position.
 4. The case (100) of claim 1, wherein the one or more hinges (103) are formed by channel or groove (119) formed on an inside face of the flexible material cover portion
 5. The case (100) of claim 1, the case (100) further comprising: a stiffener portion (105), the stiffener portion (105) adapted to connect to the inner flexible material cover portion (104) along a spine (106) of the case (100) and connect to rear portion (102).
 6. The case (100) of claim 5, wherein the spine is formed by the stiffener portion (105) and the inner flexible material portion (104).
 7. The case (100) of claim 5, wherein the stiffener portion (105) connects to the outer chassis portion (112) of the rear portion.
 8. The case (100) claim 1, wherein at least one of the inner chassis portion (114) and the internal flexible material cover portion (104) includes a texture formed in the flexible material.
 9. The case (100) of claim 1, wherein the inner chassis portion (114) includes an open area (115) for attaching the cover to the outer chassis portion (112).
 10. The case (100) of claim 1 wherein the case (100) is substantially opaque.
 11. The case (100) of claim 1 wherein the case (100) is at least partially transparent.
 12. The case (100) of claim 1, wherein the external front cover (101) and internal flexible material cover portion (104) form a flush external surface of the cover (101) of the case at the one or more hinges (103).
 13. The case (100) of claim 1, wherein the case (100) is constructed with at least one opening positioned such that a phone function of the electronic device can be used when the cover is closed.
 14. The case (100) claim 1, wherein the inner flexible material cover portion (104) forms an inner layer along the portion of the stiffener portion (105) that attaches to the rear portion (102) such that it completes the opening (115) formed by the inner chassis portion (114).
 15. The case (100) of claim 1, wherein the hard material is an engineering plastic, hardened plastic, or metal.
 16. The case (100) of claim 14, wherein the engineering plastic is selected from the group of polycarbonate and ABS.
 17. The case (100) of claim 2, further comprising the plurality of hinges (103 a, 103 b) having a bend radius of at least about 90 degrees.
 18. The case (100) of claim 1, wherein the case further comprises: an opening (117) in the rear portion (102) case (100) to allow operation of a camera for the device, wherein the front cover (101) when in a fully open position does not block the camera opening (117).
 19. The case (100) of claim 18, wherein the device includes a flash insert (111) in the camera opening (117).
 20. A method of making a case as described in each of the above claims (100) comprising: molding an outer chassis portion (112) comprising a hard material; overmolding the outer chassis portion (112) with an inner chassis portion (114) comprising an flexible material to form a rear portion (102) of the case (100); molding the one or more face covers (101 a,101 b); affixing a stiffener portion (105) in a molding tool; overmolding the one or more face covers (101 a, 101 b) with the internal, flexible material cover portion (104), such that the external front cover (101) and internal flexible material cover portion (104) form an external surface of the cover (101) of the case comprising one or more hinges (103 a, 103 b) configured to allow the one or more face covers (101 a, 101 b) to open and close over an electronic device when the device is in the case (100); and connecting the cover including the stiffener to the rear portion (102). 